EP1952917A2 - Herstellungsverfahren für eine Komponente durch Verdichtung von Pulvermaterial - Google Patents
Herstellungsverfahren für eine Komponente durch Verdichtung von Pulvermaterial Download PDFInfo
- Publication number
- EP1952917A2 EP1952917A2 EP08250213A EP08250213A EP1952917A2 EP 1952917 A2 EP1952917 A2 EP 1952917A2 EP 08250213 A EP08250213 A EP 08250213A EP 08250213 A EP08250213 A EP 08250213A EP 1952917 A2 EP1952917 A2 EP 1952917A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- workpiece
- union piece
- aerofoil
- alignment feature
- faying
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
- B23P6/005—Repairing turbine components, e.g. moving or stationary blades, rotors using only replacement pieces of a particular form
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/04—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from several pieces
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/005—Repairing methods or devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/22—Manufacture essentially without removing material by sintering
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/60—Assembly methods
- F05D2230/64—Assembly methods using positioning or alignment devices for aligning or centring, e.g. pins
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49718—Repairing
- Y10T29/49732—Repairing by attaching repair preform, e.g., remaking, restoring, or patching
- Y10T29/49734—Repairing by attaching repair preform, e.g., remaking, restoring, or patching and removing damaged material
- Y10T29/49737—Metallurgically attaching preform
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49895—Associating parts by use of aligning means [e.g., use of a drift pin or a "fixture"]
Definitions
- This invention relates to a method of manufacturing an aerofoil component using a consolidated powder material union piece and articles so manufactured.
- US 5,788,142 describes a method of joining components using an intermediate part of compacted and formed particles.
- the compacted intermediate part is formed of constituent elemental particles which in admixture provide a composition similar to the composition of the components.
- the intermediate part is formed as a sheet.
- Aerofoils used in turbine engines may be grouped into a unitary assembly of similar aerofoils, commonly, and generally known in the industry as a blisk.
- Blisks are high value components and are at risk from sustaining damage from handling and machining operations as well as sustaining in service damage from ingestion of foreign objects into the engine or by erosion or wear to the aerofoils. Because of their high value it is desirable to repair damaged portions of blades and disks to return the blisk into service.
- a method of manufacturing an aerofoil component comprising a first workpiece joined to a second workpiece, the method comprising, providing a first workpiece and a second workpiece, providing a union piece formed of partially sintered powder, the union piece having an alignment feature for aligning the first workpiece with the second workpiece, assembling the first workpiece to the second workpiece via the alignment feature, and applying heat and pressure to consolidate the first workpiece, the union piece and second workpiece.
- the alignment feature comprises a recess into which at least a portion of the second workpiece is inserted.
- the second workpiece may comprise a second union piece formed of partially sintered powder and having an alignment feature complementary to the alignment feature and wherein the second workpiece is connected to the union piece via the alignment feature and the complimentary alignment feature.
- the alignment feature is a pyramidical recess and the complementary alignment feature a pyramidical projection.
- a portion of the union piece is removed following consolidation by machining.
- the first workpiece has an aerodynamic surface and the second workpiece has an aerodynamic surface and the portion of the union piece removed blends the aerodynamic surface of the first workpiece to the aerodynamic surface of the second workpiece.
- the aerodynamic surface of the first workpiece may be a pressure flank or suction flank on the aerofoil component.
- the first workpiece may have a faying surface which abuts the union piece prior to consolidation and the second workpiece a faying surface which abuts the union piece prior to consolidation, wherein the thickness of the union piece between the faying surface of the first workpiece and the faying surface of the second workpiece is less than 500 ⁇ m.
- the first workpiece may comprise part of a unitary assembly of aerofoils.
- the second workpiece may be a repair patch for the aerofoil component.
- the method may comprise the step of allocating the first workpiece with a plurality of standard zones and removing a portion of the first workpiece corresponding to at least one of the standard zones to provide a faying location, wherein the alignment feature of the union piece complements the faying location.
- the standard zones are arranged along the leading edge and /or trailing edges of the aerofoil.
- a method of repairing an aerofoil component having damage or a defect comprising the step of allocating the aerofoil with a plurality of standard zones, determining the zone in which the damage or defect resides, removing a portion of the aerofoil in accordance with the zone in which the damage or defect resides to provide a faying location, providing a union piece formed of partially sintered powder and having an alignment feature complementing the faying location, assembling a repair patch to the aerofoil via the union piece, and applying heat and pressure to consolidate the aerofoil, union piece and repair patch.
- the aerofoil 2 is formed of a material suitable for use in the gas turbine.
- Particularly preferred materials are intermetallic alloys such as gamma titanium aluminide though it will be appreciated that the invention is appropriate to metals and their constituent alloys.
- the damaged portion has a rough surface and before any repair is made the surface is machined to provide a more uniform surface finish of the order 1 ⁇ m Ra.
- the surface may be cleaned, preferably using a swab etch of HF and HNO 3 followed by an acetone swab for a titanium alloy. This provides a clean recess for attachment of a repair patch.
- a mould or other 3-dimensional scan is taken of the aerofoil blade to determine the shape of the union piece required.
- the union piece itself is formed of a powder with a particle diameter typically below 100 ⁇ m and preferably below 50 ⁇ m in the range 20 to 40 ⁇ m.
- the powder preferably with the same nominal chemical composition of the aerofoil blade and the repair patch. Where the two components have different chemical compositions the composition of the powder is preferably an intermediate the two compositions. Other powder compositions may be used provided the function of the repaired component is not impaired.
- the manufacturing process of the union piece is depicted in Figure 2 .
- the mould is transposed to a shaped die 10 into which the powder 12 is inserted, compacted and partially sintered to form the preformed union piece 14.
- the compacting pressure is of the order 200MPa with the sintering being performed at a temperature of around 600-900°C for about 15-60 minutes.
- the union piece 14 is bespoke to the components being joined and preferably has a thickness X which between the faying surface of the aerofoil and the faying surface of the repair patch of between 200 ⁇ m and 2000 ⁇ m. For the majority of aerofoil repairs, where damage occurs to the leading or trailing edges of the blade it is desirable that the thickness is between 200 ⁇ m and 500 ⁇ m. Blade at this location have a width Y typically between 2 and 8mm.
- the union piece 14 is machined to form an alignment feature or features 16, 16'which will assist the alignment of the repair patch with the aerofoil.
- the alignment feature is at its simplest a recess or groove into which a complementary portion of the repair patch is inserted.
- Figure 3 depicts a perspective view of one embodiment of a sintered union piece 14, aerofoil 2 and repair patch 20.
- the aerofoil is inserted into the groove in the union piece till the machined faying face of the aerofoil 24 abuts a corresponding flat face 22 on the union piece.
- the union piece extends widthwise beyond the aerofoil to aid both alignment and the joining step which consolidates the union piece with the aerofoil and repair patch.
- the union piece is clamped to the aerofoil and the repair patch 20 connected to the assembly using the alignment feature of the union piece.
- the repair patch is provided with a recess which mates with the alignment features in the union piece.
- the alignment features enable the repair patch and aerofoil to be presented to each other with correct positioning. Beneficially, it is possible to create alignment features which allow the parts to be assembled in just one orientation thereby reducing the chance of mistakes. As an additional benefit, the alignment features may be sized to provide an interference fit with the repair patch or aerofoil to aid assembly and reduce the number of clamps required.
- the thickness of the union piece 14 between the faying surface 24 of the aerofoil and the faying surface 25 of the repair patch is kept below 500 ⁇ m. It has been found that the thicker the union piece, which does not have the same material structure as the virgin cast aerofoil 2 and repair patch 20, the greater the risk of pores or other deleterious artefacts damaging the integrity of the repaired aerofoil.
- the union piece is attached to the aerofoil and the alignment feature formed therein whilst the union piece is in situ.
- a shroud, jacket or bag is placed around the assembly and either evacuated or filled with an inert gas to minimise the risk of oxidation of the aerofoil or patch.
- Uniform pressure of between 25 and 100 Mpa is applied to form a butt joint and heat is applied locally to heat the union piece to a bonding temperature of between 850 and 1200°C to both fully sinter the union piece and to consolidate it with the joint surfaces.
- the components are cooled at a rate of the order 5°C / min to minimise residual stresses generated locally to the join.
- a post join heat treatment may be used to further reduce residual stresses.
- the repair patch may also be provided with a union piece as depicted in Figure 4 .
- both the aerofoil 2 and the repair patch are provided with separate union pieces formed from sintered powder as described above.
- the union pieces are easier to machine than the aerofoil and repair patch particularly when these components are formed of an intermetallic material such as titanium gamma aluminide.
- the union pieces are easier to machine it is possible to provide better and more elaborate alignment features.
- the alignment feature in the first union piece 14 is a pyramidical projection 26. Such alignment features aid the butting of the union pieces and consequently the joining of the aerofoil with the repair patch.
- the union piece may be formed primarily as a generic cube which is machined to its final dimensions.
- the union piece may be formed by a process of direct metal deposition where powder or wire is fed onto a substrate, which may be the aerofoil blade, whilst the substrate is heated and partially melted by a traversing laser beam.
- the traversing beam forms a melt pool into which the powder is directed and melted.
- the melt pool cools the powder solidifies to provide a deposit with a height.
- Repeated passes of the laser over the deposit enables layers of powder to be repeatedly provided, partially melted and solidified thereby increasing the height of the deposit.
- Beneficially manufacturing via this route as the laser partially sinters the powder, it is possible to dispense of an additional partial sinter step. In some circumstances it may be possible to sinter the material without heating it to a temperature at which it melts.
- the above described invention provides a relatively simple and low-cost solution for repairing complex geometries.
- the repair process can be automated.
- the invention has been described with respect to having union pieces specifically designed for the repair required. Because the union piece has to be manufactured using specialist equipment this can be time consuming, particularly where the piece needs to be ordered for manufacture. It is desirable to have the union piece, where possible, as a stock item. Where the piece is a stock item the repair patch may also be a stock item and pre-arranged with the union piece.
- the zone in which it occurs is determined through routine inspection. Material is removed from the blade 2 to match the profile of the standard zone in which it is found. Removal of material to the standard zone can result the much more of the aerofoil being machined away than strictly required to simply provide a surface suitable for attaching a new repair, as shown in Figure 6 where the damage 4 occurs in zone 32 and the whole of zone 32 is removed.
- a number of stock union pieces equivalent for each of the zones are manufactured and supplied to the repair facility in advance.
- the repair patch 20 may be preassembled to the union piece allowing the piece to be tested prior to supply.
- the union piece is assembled to the aerofoil following the procedure detailed above.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- General Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Materials Engineering (AREA)
- Powder Metallurgy (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GBGB0701904.5A GB0701904D0 (en) | 2007-02-01 | 2007-02-01 | A method of manufacturing a component by consolidating powder material |
Publications (3)
Publication Number | Publication Date |
---|---|
EP1952917A2 true EP1952917A2 (de) | 2008-08-06 |
EP1952917A3 EP1952917A3 (de) | 2010-01-20 |
EP1952917B1 EP1952917B1 (de) | 2011-12-21 |
Family
ID=37891091
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP08250213A Expired - Fee Related EP1952917B1 (de) | 2007-02-01 | 2008-01-16 | Herstellungsverfahren für eine Komponente durch Verdichtung von Pulvermaterial |
Country Status (4)
Country | Link |
---|---|
US (1) | US8141225B2 (de) |
EP (1) | EP1952917B1 (de) |
GB (1) | GB0701904D0 (de) |
SG (1) | SG144880A1 (de) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2011009431A1 (de) * | 2009-07-18 | 2011-01-27 | Mtu Aero Engines Gmbh | Verfahren zum austauschen einer schaufel eines rotors mit integrierter beschaufelung und ein derartiger rotor |
FR2949366A1 (fr) * | 2009-08-31 | 2011-03-04 | Snecma | Realisation par procede mim d'un morceau de piece pour la reparation d'une aube de distributeur de turbine |
CN103624493A (zh) * | 2013-11-26 | 2014-03-12 | 中国南方航空工业(集团)有限公司 | 航空发动机的压气机对半机匣的加工方法 |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9700941B2 (en) * | 2012-10-03 | 2017-07-11 | Siemens Energy, Inc. | Method for repairing a component for use in a turbine engine |
GB201405988D0 (en) | 2014-04-03 | 2014-05-21 | Rolls Royce Plc | Bonding method |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5788142A (en) | 1995-10-04 | 1998-08-04 | Societe Nationale D'etude Et De Construction De Moteurs D'aviation "Snecma" | Process for joining, coating or repairing parts made of intermetallic material |
Family Cites Families (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3429700A (en) | 1966-09-20 | 1969-02-25 | Teleflex Inc | Method of producing composite metal articles by uniting two identical shapes |
GB1224521A (en) * | 1968-03-27 | 1971-03-10 | Rolls Royce | Method of making an aerofoil-shaped blade or blade blank |
US3905723A (en) * | 1972-10-27 | 1975-09-16 | Norton Co | Composite ceramic turbine rotor |
US4172107A (en) * | 1975-11-10 | 1979-10-23 | Tokyo Shibaura Electric Co., Ltd. | Method of manufacturing composite ceramic articles |
JPS5841775A (ja) | 1981-09-07 | 1983-03-11 | 大同特殊鋼株式会社 | セラミツクス−金属複合体の製造方法 |
JPS5964185A (ja) | 1982-10-06 | 1984-04-12 | Toyota Motor Corp | 焼結部材の接合方法 |
JPS61197476A (ja) | 1985-02-26 | 1986-09-01 | 株式会社東芝 | 複合体およびその製造方法 |
US4594219A (en) | 1985-08-02 | 1986-06-10 | Metals, Ltd. | Powder metal consolidation of multiple preforms |
JPS6372804A (ja) | 1986-09-12 | 1988-04-02 | Fujitsu Ltd | 焼結部品の製造方法 |
JPH08225811A (ja) | 1995-02-20 | 1996-09-03 | Olympus Optical Co Ltd | 金属粉末またはセラミクス粉末焼結体 およびその製造方法 |
DE102005019077A1 (de) * | 2005-04-23 | 2006-10-26 | Mtu Aero Engines Gmbh | Schaufel einer Strömungsmaschine und Verfahren zur Herstellung und/oder Reparatur derselben |
-
2007
- 2007-02-01 GB GBGB0701904.5A patent/GB0701904D0/en not_active Ceased
-
2008
- 2008-01-16 EP EP08250213A patent/EP1952917B1/de not_active Expired - Fee Related
- 2008-01-17 US US12/007,961 patent/US8141225B2/en not_active Expired - Fee Related
- 2008-01-25 SG SG200800727-0A patent/SG144880A1/en unknown
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5788142A (en) | 1995-10-04 | 1998-08-04 | Societe Nationale D'etude Et De Construction De Moteurs D'aviation "Snecma" | Process for joining, coating or repairing parts made of intermetallic material |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2011009431A1 (de) * | 2009-07-18 | 2011-01-27 | Mtu Aero Engines Gmbh | Verfahren zum austauschen einer schaufel eines rotors mit integrierter beschaufelung und ein derartiger rotor |
US9138834B2 (en) | 2009-07-18 | 2015-09-22 | Mtu Aero Engines Gmbh | Method for replacing a blade of a rotor having integrated blades and such a rotor |
FR2949366A1 (fr) * | 2009-08-31 | 2011-03-04 | Snecma | Realisation par procede mim d'un morceau de piece pour la reparation d'une aube de distributeur de turbine |
CN103624493A (zh) * | 2013-11-26 | 2014-03-12 | 中国南方航空工业(集团)有限公司 | 航空发动机的压气机对半机匣的加工方法 |
CN103624493B (zh) * | 2013-11-26 | 2016-03-23 | 中国南方航空工业(集团)有限公司 | 航空发动机的压气机对半机匣的加工方法 |
Also Published As
Publication number | Publication date |
---|---|
SG144880A1 (en) | 2008-08-28 |
EP1952917B1 (de) | 2011-12-21 |
EP1952917A3 (de) | 2010-01-20 |
GB0701904D0 (en) | 2007-03-14 |
US8141225B2 (en) | 2012-03-27 |
US20100281669A1 (en) | 2010-11-11 |
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